Low Organic Vapor Permeation Resin Composition

ABSTRACT

The invention relates to a novel composition comprising at least one polyphthalamide reactively extruded with at least one other polyamide, a polyester, and a modifier. The composition can be further modified with fillers to add increased strength. Other additives such as colorants, flame retardants, and UV degradation inhibitors are also contemplated. This composition exhibits superior barrier to organic vapors, impact strength and heat distortion temperatures. Also disclosed are articles using this novel composition such as fuel tanks for gasoline engines used to power lawn mowers and garden machinery.

This patent application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 11/445,113 filed on Jun. 1, 2006; both of whichclaim priority from U.S. Provisional Patent Application No. 60/686,315titled, LOW ORGANIC VAPOR PERMEATION RESIN COMPOSITION, filed Jun. 1,2005.

FIELD

This invention relates to compatibilized thermoplastic blends comprisingpolyphthalamide and an aromatic polyester used for molded articlesrequiring high barrier to organic vapors.

BACKGROUND

In the automotive industry polymeric fuel containers are being usedbecause they can be manufactured in a cost-efficient manner, are of highmechanical stability and readily deformable in accidents, and greatlyinhibit hydrocarbon permeation. The best results as to the overallqualities of the polymeric fuel containers have been obtained by asix-layer so-called COEX-structure. This is a multi-layer systemmanufactured in a single process (co-extrusion) and including two layersof high density polyethylene (HDPE) which enclose a barrier-layer of anethylene vinyl alcohol copolymer (EVOH) and a layer of treated, recycledor “re-grind” plastic material.

The EVOH-layer, which is not directly connectable to the HDPE, has anadhesive layer provided on both of its sides for connection to theadjacent layers so that the total structure comprises six layers. Thelayer of recycled or re-grind material is of a thickness which is about35 to 45% of the total thickness of the fuel container wall and consistsof a mixture of scrap materials resulting from the manufacturing ofcontainers, i.e. it is both of HDPE and of EVOH. While HDPE is cheap andhas good mechanical characteristics, it is a poor barrier againstpermeation of hydrocarbons. This is why the relatively thin EVOH-layeris used, which while being expensive, is an excellent barrier againstpermeation of hydrocarbons. Additional techniques include fluorinatingthe polyethylene to make it inherently more impermeable to fuel vapors.

Presently, the State of California generally has the most stringentrequirements for the reduction of total vehicle hydrocarbon emissions.As a general rule the other states in the U.S. and many other countrieswill adopt the Californian regulations after some time. Under theprovisions of such future regulations the level of total vehiclehydrocarbon permeation must not exceed 0.5 g per day. To achieve thislevel, it has been estimated that the hydrocarbon emissions from thevehicle fuel system must not be more than 150 mg per day, which wouldresult in a static permeation of less than 55 mg per day when productionand durability parameters are considered. However, the fuel container isonly a part of the total fuel system, and further estimates have shownthat permeation through the container wall should not exceed 5 mg perday in order to meet the above requirements. The above described typicalsix-layer COEX-structure, however, only provides permeation levels ofabout 20 mg or less per day. One possibility to improve the performanceof the six-layer COEX-structure would be to increase the thickness ofthe EVOH-layer from about 150 micrometers to about 1.0 mm. Apart fromsubstantially increased costs this would cause production problems anddeteriorate the mechanical properties of the fuel container because EVOHhas relatively poor impact resistance. This structure also has apermeation window which results when the two wall halves are weldedtogether by pinching under heat.

U.S. Pat. No. 6,719,163 teaches eliminating the 6 layer co-extrudedstructure and its associated permeation window, with a multilayerstructure containing two separately manufactured halves with the barrierlayer on the outside of the structure. U.S. Pat. No. 6,719,163 teachesthe layers of its fuel tank be made of high density polyethylene and acompound impermeable to fuel such as ethyl vinyl alcohol (EVOH).

European Patent EP 742 236 describes petrol tanks consisting of fivelayers which are, respectively: high density polyethylene (HDPE); abinder; a polyamide (PA) or a copolymer containing ethylene units andvinyl alcohol units (EVOH); a binder; and HDPE.

A sixth layer can be added between one of the layers of binder and oneof the HDPE layers. This sixth layer consists of manufacturing scrapsfollowing molding of the tanks, and to a much smaller extent ofnon-compliant tanks These scraps and non-compliant tanks are then grounduntil granules are obtained. This ground material is then re-melted andextruded directly at the tank co-extrusion plant. This ground materialmay also be melted and re-granulated by means of an extruding machinesuch as a twin-screw extruder, before being reused.

According to one variant, the recycled product can be mixed with theHDPE from the two extreme layers of the tank. It is possible, forexample, to mix the granules of recycled product with granules of virginHDPE of these two layers. It is also possible to use any combination ofthese two recyclings. The content of recycled material can represent upto 50% of the total weight of the tank.

European Patent EP 731 308 describes a tube comprising an inner layercomprising a mixture of polyamide and of polyolefin with a polyamidematrix and an outer layer comprising a polyamide. These tubes based onpolyamide are useful for transporting petrol and more particularly forbringing the petrol from the motor vehicle tank to the motor and also,but in larger diameter, for transporting hydrocarbons in servicestations between the distribution pumps and the underground storagetanks

According to another form of the tube, a layer of a polymer comprisingethylene units and vinyl alcohol units (EVOH) can be placed between theinner and outer layers. The structure: inner layer/EVOH/binder/outerlayer is advantageously used.

The tanks described in EP 742 236 which do not have the barrier layer indirect contact with the petrol do admittedly have barrier properties,but they are not sufficient when very low petrol losses are desired. EP731 308 describes tubes whose outer layer is made of polyamide and thebarrier layer is in direct contact with the petrol, wherein the layermade of polyamide is necessary for the mechanical strength of theassembly.

United States Patent Application No. 20030198768 proposes a plastic fueltank having a multilayer wall structure, wherein a barrier layer formsan exposed face of the wall and preferably is in direct contact with thefuel contained therein. The barrier layer of the structures of theinvention constitutes one of the exposed faces of the structure, i.e. itis not an interior layer of the wall structure. Fuel tank structuresembodying the invention have walls with HDPE/barrier layer orHDPE/binder/barrier layer, in which “HDPE” denotes high densitypolyethylene.

The preferred fuel tank of United States Patent Application No.20030198768, comprises successively: a first layer of high densitypolyethylene (HDPE), a layer of binder, a second layer of EVOH or of amixture based on EVOH, and optionally a third layer of polyamide (A) ora mixture of polyamide (A) and polyolefin (B).

The polyamides proposed in United States Patent Application No.20030198768 are those in which the term “polyamide” means the followingproducts of condensation of one or more amino acids, such asaminocaproic acid, 7-aminoheptanoic acid, 11-aminoundecanoic acid and12-aminododecanoic acid of one or more lactams such as caprolactam,oenantholactam and lauryllactam; and of one or more salts or mixtures ofdiamines such as hexamethylenediamine, dodecamethylenediamine,meta-xylylenediamine, bis(p-aminocyclohexyl)methane andtrimethylhexamethylenediamine with diacids such as isophthalic acid,terephthalic acid, adipic acid, azelaic acid, suberic acid, sebacic acidand dodecanedicarboxylic acid.

As examples of polyamides, United States Patent Application No.20030198768 mentions PA 6 and PA 6-6 and copolyamides. United StatesPatent Application No. 20030198768 also mentions copolyamides resultingfrom the condensation of at least two α,{acute over (ω)}-aminocarboxylicacids or of two lactams or of one lactam and one α,{acute over(ω)}-aminocarboxylic acid. Also included in United States PatentApplication No. 20030198768 are the copolyamides resulting from thecondensation of at least one α,{acute over (ω)}-aminocarboxylic acid (ora lactam), at least one diamine and at least one dicarboxylic acid.

United States Patent Application No. 20030198768 prefers lactamscontaining from 3 to 12 carbon atoms on the main ring and which can besubstituted. Examples of such lactams are β,β-dimethylpropiolactam,α,α-dimethylpropiolactam, amylolactam, caprolactam, capryllactam andlauryllactam.

Aminoundecanoic acid and aminododecanoic acid are examples of α,{acuteover (ω)}-aminocarboxylic acids and adipic acid, sebacic acid,isophthalic acid, butanedioic acid, 1,4-cyclohexanedicarboxylic acid,terephthalic acid, sodium or lithium salts of sulphoisophthalic acid,dimerized fatty acids (these dimerized fatty acids have a dimer contentof at least 98% and are preferably hydrogenated) and dodecanedioic acidHOOC—(CH₂)₁₀—COOH are examples of dicarboxylic acids.

The diamine noted in United States Patent Application No. 20030198768can be an aliphatic diamine containing from 6 to 12 atoms and can bearylic and/or saturated cyclic. Hexamethylenediamine, piperazine,tetramethylenediamine, octamethylenediamine, decamethylenediamine,dodecamethylenediamine, 1,5-diaminohexane,2,2,4-trimethyl-1,6-diaminohexane, diaminepolyols, isophoronediamine(IPD), methylpentamethylenediamine (MPDM), bis(aminocyclohexyl)methane(BACM) and bis(3-methyl-4-aminocyclohexyl)methane (BMACM) are examplesof such diamines.

Copolymers of caprolactam and of lauryllactam (PA 6/12), copolymers ofcaprolactam, of adipic acid and of hexamethylenediamine (PA 6/6-6),copolymers of caprolactam, of lauryllactam, of adipic acid and ofhexamethylenediamine (PA 6/12/6-6), copolymers of caprolactam, oflauryllactam, of 11-aminoundecanoic acid, of azelaic acid and ofhexamethylenediamine (PA 6/6-9/11/12), copolymers of caprolactam, oflauryllactam, of 11-aminoundecanoic acid, of adipic acid and ofhexamethylenediamine (PA 6/6-6/11/12) and copolymers of lauryllactam, ofazelaic acid and of hexamethylenediamine (PA 6-9/12) are examples ofcopolyamides. The problem with the use of most polyamides is highshrinkage from the mold. Polyamides also present a problem of highmoisture absorption which can result in broken seals at the welds andseams of the two halves of the fuel tank.

U.S. Pat. No. 5,441,781 teaches a multi-layer plastic fuel tankcomprising (A) a gas barrier layer having on at least one side thereof(B) an adhesive layer and further thereon (C) a high-densitypolyethylene layer, the gas barrier layer (A) comprising a resin havinggas barrier properties, the adhesive layer (B) comprising a resin havingadhesiveness to both of the gas barrier layer (A) and the high-densitypolyethylene layer (C), the high-density polyethylene layer (C)comprising high-density polyethylene having an intrinsic viscosity offrom 2 to 6 dl/g, a density of from 0.940 to 0.970 g/cm³, and a zeroshear viscosity of from 2.0×10⁷ to 1.0×10⁸ poise at 190° C.

The multi-layer plastic fuel tank according to U.S. Pat. No. 5,441,781comprises gas barrier layer (A) having laminated on at least one sidethereof high-density polyethylene layer (C) via adhesive layer (B).

Resins with gas barrier properties are used in gas barrier layer (A).Examples include a modified polyamide composition comprising a mixtureof (1) an α,β-unsaturated carboxylic acid-modified ethylene-α-olefincopolymer prepared by grafting an α,β-unsaturated carboxylic acid or aderivative thereof to an ethylene-.α-olefin copolymer at a graftingratio of from 0.05 to 1% by weight, preferably from 0.2 to 0.6% byweight, based on the ethylene-.α-olefin copolymer and (2) a polyamide.The ethylene-α-olefin copolymer, preferably has a degree ofcrystallinity of from 1 to 35%, more preferably from 1 to 30%, and amelt index of from 0.01 to 50 g/10 min, more preferably from 0.1 to 20g/10 min. Examples of the α,β-unsaturated carboxylic acid or aderivative thereof include monocarboxylic acids, such as acrylic acidand methacrylic acid, their derivatives, dicarboxylic acids, such asmaleic acid, fumaric acid and citraconic acid, and their derivatives.Preferred examples of the α,β-unsaturated carboxylic acid or aderivative thereof include maleic anhydride.

Examples of the α-olefins in the ethylene-α-olefin copolymer (1) includepropylene, butene-1, hexene-1, etc. The α-olefin is generallycopolymerized with ethylene at a ratio of not more than 30% by weight,and preferably from 5 to 20% by weight, based on the total amount of thecopolymer.

The polyamide (2) generally has a relative viscosity of from about 1 to6. Examples of the polyamide include polyamides obtained bypolycondensation of a diamine and a dicarboxylic acid, polyamideobtained by polycondensation of an aminocarboxylic acid, polyamideobtained by polycondensation of a lactam, and copolyamide thereof.

Examples of the diamine includes aliphatic, alicyclic or aromaticdiamines, such as hexamethylenediamine, decamethylenediamine,dodecamethylenediamine, trimethylhexamethylenediamine,1,3-bis(aminomethyl)cyclohexane, 1,4-bis(aminomethyl)cyclohexane,bis(p-aminocyclohexylmethane), m-xylylenediamine, and p-xylylenediamine.Examples of the dicarboxylic acid includes aliphatic, alicyclic oraromatic dicarboxylic acids, such as adipic acid, suberic acid, sebacicacid, cyclohexanedicarboxylic acid, terephthalic acid, and isophthalicacid. Examples of the aminocarboxylic acid includes ε-aminocaproic acidand 11-aminoundecanoic acid. Examples of the lactam includesε-caprolactam and ε-laurolactam.

Specific examples of the polyamide include nylon 6, nylon 66, nylon 610,nylon 9, nylon 11, nylon 12, nylon 6/66, nylon 66/610, and nylon 6/11.

From the standpoint of moldability, a polyamide having a melting pointof from 170 to 280° C., and particularly from 200 to 240° C., istypical. Nylon 6 is quite suitable for the use.

The α,β-unsaturated carboxylic acid-modified ethylene-α.-olefincopolymer is generally mixed with the polyamide in an amount of from 10to 50 parts by weight, and preferably from 10 to 30 parts by weight, per100 parts by weight of the polyamide.

Other solutions to increasing the barrier of fuel tanks can be found inU.S. Pat. No. 5,129,544 which teaches a laminate structure with achemical resistant layer such as nylon 12 and Teflon. U.S. Pat. No.5,547,096 teaches a fuel tank of an inner and outer shell where theouter shell is electroplated with successive layers of copper, nickeland chrome. U.S. Pat. No. 6,409,040 teaches injection molding two halveswhere the barrier layer is formed on the outer wall as a coat of paint.

There therefore exists, the need for a single composition which can beused as a monolayer or as a barrier layer in the multilayer structurewhich is impermeable to fuel vapors and has the necessary mechanicalstrength to function as a fuel container.

SUMMARY

This invention relates to a thermoplastic resin comprising an aromaticpolyester, a polyphthalamide and a compatibilizer. More specifically,the aromatic polyester is selected from the group consisting ofpolybutylene terephthalate, polyethylene terephthalate, polytrimethyleneterephthalate, polyethylene naphthalate, and polybutylene naphthalate.The compatibilizer has at least one functional group selected from thegroup consisting of hydroxyl groups, carboxylic acid groups, glycidylgroups, maleic anhydride groups, amino groups, siloxane groups orisocyanato groups. More specifically the composition may furthercomprise a second polyamide selected from the group consisting ofaliphatic polyamides and partially aromatic polyamides.

Also disclosed is a fuel tank having a contained volume wherein saidfuel tank is comprised of at least one wall, an inlet, an outlet,wherein the wall is comprised of the thermoplastic composition mentionedabove and the wall is of monolayer construction.

The container also is used for organic liquids having a contained volumewherein said container is comprised of at least one wall, wherein saidcontainer is connected with an energy conversion device in such a mannerthat organic liquid stored in the container is capable of beingtransferred from the container to the energy conversion device andwherein the wall is comprised of a thermoplastic composition specified.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 depicts a representative fuel tank as viewed from the top view.

FIG. 2 depicts the representative fuel tank as viewed from the side.

FIG. 3 depicts the representative fuel tank as viewed from the front.

FIG. 4 depicts a different representative fuel tank design.

DETAILED DESCRIPTION

This specification describes a novel composition made by reactivelyextruding at least one polyphthalamide with, at least one aromaticpolyester, at least one compatibilizer, and optionally another polyamidewhich is partially aromatic or aliphatic and up to 70 weight percent ofat least one filler which may or may not provide reinforcing properties.The properties of this composition when formed into a fuel containerprovide the necessary strength and improved barrier properties to makeit a good material for fuel tanks

Polyamides suitable for this invention can be described as comprisingthe reaction product of amino caproic acid with itself or a repeatingunit A-D, wherein A is the residue of a dicarboxylic acid comprisingadipic acid, isophthalic acid, terephthalic acid,1,4-cyclohexanedicarboxylic acid, resorcinol dicarboxylic acid, ornaphthalenedicarboxylic acid and D is a residue of a diamine comprisingm-xylylene diamine, p-xylylene diamine, hexamethylene diamine, ethylenediamine, para-phenylenediamine or 1,4 cyclohexanedimethylamine, ormixtures thereof. These polyamides can range in number average molecularweight from 2,000 to 60,000 as measured by end-group titration.

Whether a polyamide is aliphatic, partially aromatic or fully aromaticdepends upon the nature of the acid and diamine. If both are aliphatic,then the subsequent polymer is an aliphatic polyamide. The reactionproduct of adipic acid, (an aliphatic dicarboxylic acid) andhexamethylene diamine is the well known aliphatic polyamide called Nylon66. If the acid and diamine contain aliphatic and aromatic constituents,the resulting polymer is considered partially aromatic. The reactionproduct of adipic acid and m-xylylene diamine is a partially aromaticpolyamide known as nylon MXD-6. If both the acid and diamine arearomatic, then the resulting polymer is an aromatic polyamide.

The aromatic polyamides that can be utilized in the practice of thisinvention are made by condensation polymerization wherein an aromaticdicarboxylic acid is reacted with an aromatic diamine. A suitablearomatic polyamide is polyphthalamide (PPA). In its generic sense, thepolyphthalamide is the reaction product of a phthalate with a diamine.Examples of the phthalates are terephthalate (terephthalic acid),isophthalate (isophthalic acid), or orthophthalate. A preferredpolyphthalamide can be made by the polymerization of terephthalic acidwith para-phenylenediamine. Polyphthalamide is a semi-crystallinepolymer that can be represented by the structural formula:

wherein n is an integer that represents the number of repeat units inthe polymer.

Although not a phthalate,the use of 2,6 naphthalate (naphthalatedicarboxylic acid) is also contemplated.

U.S. Pat. No. 4,603,193, the teachings of which are incorporated herein,describes a salt process to manufacture polyphthalamides. That processcomprises preparing a salt of an aliphatic or aromatic diamine or amixture of these and di, tri or tetracarboxylic acid, a mixture of theseor their corresponding anhydrides by reacting both feedstocks at atemperature of about 375° F. to about 450° F. in an aqueous mediumprovided the water content of the resulting solution is kept below 25%water by weight. The resulting salt solution is subjected to a pressureof about 1500 to about 3000 psig and is then passed through a preheatzone where the temperature is increased from about 425° F. to about 625°F., the total residence time is kept about 25 to about 50 seconds, thereactants then are flashed through a control valve or nozzle to give anaerosol mist at a pressure of about 0 to about 400 and melt temperaturesof about 500° F. to about 750° F. The total residence time in thereactor being about 0.1 to about 20 seconds. The polymer is theninjected onto the screws of a twin screw reactor. The residence time inthe extruder is about 45 seconds to about 3 minutes.

Examples of polymers manufactured by the salt process are the polyamidesprepared from hexamethylene diamine and terephthalic acid, isophthalicacid and adipic acid in the mole ratio of about 100:65:25:10; to about100:85:5:10; and the polyamides which are prepared from hexamethylenediamine, terephthalic acid and isophthalic acid in the mole ratio ofabout 100:30:70 to about 100:90:10.

U.S. Pat. No. 5,175,238, the teachings of which are incorporated herein,describes one composition of high barrier polyphthalamide as having amolar ratio of isophthalic acid/terephthalic acid/adipicacid/metaxylylenediamine/hexamethylenediamine in the range of30-5/0-15/20-30/30-20/30-20.

Polyphthalamide is commercially available from Solvay Advanced Polymersand is sold as Amodel® PPA. The Amodel® grades of 1002 and 1006 differin that the 1002 has a polyolefin impact modifier, the other is neat.

U.S. Pat. No. 5,194,577 states that polyphthalamides can be preparedfrom the appropriate starting materials, e.g., a dicarboxylic acidcomponent comprising terephthalic acid and adipic acid, or theirderivatives, and a diamine component comprising meta-xylylene diamineand a divalent straight-chain or cyclic aliphatic diamine of about 4 toabout 20 carbon atoms having up to one methyl substituent per carbonatom, preferably hexamethylene or octamethylene diamine and derivativesthereof, in suitable proportions by any suitable means. The dicarboxylicacid component and diamine component are used in essentiallystoichiometric quantities although a slight excess of either, e.g., upto about 10 mole percent, can be used to account for loss of reactantsor to provide final products with a predominance of acid or amine endgroups as desired. One suitable preparation involves a salt preparationstep, preferably conducted batchwise to achieve proper stoichiometry,wherein dicarboxylic acid and diamine components and solvent are addedto a suitable reaction vessel in appropriate amounts and maintainedunder conditions effective to cause salt formation but avoid appreciableconversion of salts to oligomers. Water is a preferred solvent andtemperature is preferably maintained below about 120° C. to minimizeconversion. Product of the salt preparation step can be introduced intoa condensation section operated either batchwise or continuously. In thecondensation section substantial conversion of salts to polymer takesplace. The condensation product then typically is introduced into afinishing section, such as a twin-screw extruder, to obtain furtherconversion and increase inherent viscosity from a level of about 0.1 toabout 0.6 dl/g typically achieved in the condensation section up toabout 0.8 dl/g or greater. The polymeric product can be recovered fromthe finishing section and, for example, pelletized or mixed withfillers, additives and the like. Other suitable methods for preparationof such polyphthalamides by a process particularly suited for highmelting polyamides. The process of the latter comprises forming anessentially homogeneous mixture of polyamide-forming starting materials,transferring the mixture to a heated preflash zone under pressure,passing the heated, pressurized mixture through an orifice into a zoneof lower pressure and high heat flux to form an aerosol mist ofreactants, passing the aerosol mist through the zone of high heat fluxat low residence time and passing the resulting product to a finishingreactor to increase conversion thereof.

U.S. Pat. No. 4,603,166, the teachings of which are incorporated herein,describes how to make polyphthalamides in either a batch or continuousprocess. The patent also teaches how to compound the polyphthalamides aswell.

U.S. Pat. No. 4,617,342, the teachings of which are incorporated herein,describes a crystalline polyamide which has improved tensile strengthand which has a heat deflection temperature in excess of 240° C. whenfilled is formed from dicarboxylic acid compounds comprising compoundsof terephthalic acid and isophthalic acid in a molar ratio of at least80:20 to about 99:1 and diamines comprising hexamethylene diamine andtrimethylhexamethylene diamine in a molar ratio of about 98:2 to about60:40.

The polyesters useful in the composition are the polycondensationreactions of at least one dicarboxylic acid, or its dimethyl ester, witha di-alcohol. Suitable polyesters are the aromatic polyesters such aspolyethylene terephthalate, also known as PET, made from the reaction ofterephthalic acid with ethylene glycol, polybutylene terephthalate, alsoknown as PBT, which is the reaction product of terephthalic acid with1,4 butane diol, and poly(trimethylene terephthalate), also known asPTT, which is the reaction product of terephthalic acid with 1,3 propanediol. PET, PBT, and PTT are available from many suppliers in manygrades, usually modified by adding at least one additional co-monomer.The co-monomer could be another alcohol, such as diethylene glycol orcyclohexane dimethanol, or dicarboxylic acid, or both. Therefore, thephrase polyethylene terephthalate, polyethylene naphthalate,polybutylene naphthalate, polyethylene isophthalate, polybutyleneisophthalate, polybutylene terephthalate, poly(trimethyleneterephthalate), poly(trimethylene isophthalate), and poly(trimethylenenaphthalate) include the homopolymer and copolymer variations. The termcopolymer includes terpolymers and polymers with at least threecomonomers and unlimited number of total monomers. The typical intrinsicviscosity of these polyesters is at least 0.4 but less than 1.2 dl/g.

The compatibilizer is preferably a functionalized rubbery polymer and istypically an ethylene copolymer that functions as a compatibilizingagent or surfactant, in that it forms a covalent bond and/or physicalinteraction with the polyester and polyphthalamide component, and blendscompatibly with the polyphthalamide component. In most cases, to get thehigh level of compatibility and physical properties, such as lowtemperature impact strength, a covalent bond will form between thepolyester component and the functionalized rubbery polymer. Thefunctionalized rubbery polymer component of the thermoplastic resincomposition will normally represent from 2.0 weight percent to 25 weightpercent of the polymers in the composition, with 3.0 to 10 weightpercent more preferable and 4 to 8 percent most preferable. Thefunctionalized rubbery polymer is preferably present in the compositionat a level which is within the range of 3 weight percent to 15 weightpercent.

The functionalized rubbery polymer will generally be a compatibilizingethylene copolymer of the formula E/X/Y, where E is about 55-75%, X isabout 15-35%, and Y is about 2-15% by weight of the compatibilizingethylene copolymer, and E is ethylene.

X is an α,β-ethylenically unsaturated monomer derived from at least oneof alkylacrylate, alkylmethacrylate, alkyl vinyl ether, carbon dioxide,sulfur dioxide, or mixtures thereof, where the alkyl groups contain 1-12carbon atoms, such as vinyl acetate, methylacrylate, butylacrylate, andmethyl vinyl ether. X can, for example, be a moiety derived from atleast one of alkyl acrylate, alkyl methacrylate, alkyl vinyl ether,carbon monoxide, sulfur dioxide, or mixtures thereof. More specifically,X can, for example, contain up to about 35 weight percent of a moietyderived from at least one alkyl acrylate, alkyl methacrylate, ormixtures thereof where the alkyl groups contain 1-8 carbon atoms.

Y is an α,β-ethylenically unsaturated monomer containing a reactivegroup, such as epoxide, maleic anhydride, isocyanate, or oxazoline, forexample. In one embodiment, Y is selected from the group consisting ofglycidyl methacrylate and glycidyl acrylate, maleic anhydride, andisocyanato-ethylmethacrylate.

The functionalized rubbery polymer will typically contain repeat unitsthat are derived from an acrylate monomer of the structural formula:

wherein R represents a hydrogen atom, an alkyl group containing from 1to about 8 carbon atoms, or a moiety containing an epoxy group, andwherein R¹ represents a hydrogen atom or an alkyl group containing from1 to about 8 carbon atoms. Some representative examples of monomers thatcan be used include methyl methacrylate, butyl acrylate,dimethylsiloxane. In many cases, R will represent an alkyl groupcontaining from 1 to 4 carbon atoms. The moiety containing an epoxygroup will typically be of the structural formula:

wherein n represents an integer from 1 to about 6. In most cases, n willrepresent 1.

The functionalized rubbery polymer will generally also contain repeatunits that are derived from a conjugated diolefin monomer, such as1,3-butadiene or isoprene, a vinyl aromatic monomer, such as styrene orα-methyl styrene, a mono-olefin monomer, such as ethylene or propylene,and/or a dialkylsiloxane monomer, such as dimethylsiloxane.

Another compatibilizer is polypropylene with 1% maleic anhydride,available as Polybond™ 3200 from Crompton Corporation. The RoyaltufProducts from Crompton Corporation are also preferred compatibilizers.These products use ethylene propylene diene monomer grafted with maleicanhydride. Of particular interest is Grade 485 with has a 75/25 Ethyleneto Propylene ratio and 0.5 weight percent maleic anhydride. Grade 498 isalso a good compatibilizer. Grade 498 has a 55/45 ethylene to propyleneratio and 1.0 weight percent maleic anhydride.

One special compatabilizer is polyethylene. The compatibilizer need notbe a single compound, but could be a mixture of the class ofcompatibilizers listed herein.

The functionalized rubbery polymer can optionally contain repeat unitsin its backbone which are derived from an anhydride group containingmonomer, such as maleic anhydride. In another scenario, thefunctionalized rubbery polymer can contain anhydride moieties which aregrafted onto the polymer in a post polymerization step.

The composition will be comprised of the polyphthalamide which ispresent in an amount within the range of about 2 weight percent to about93 weight percent on the basis of polyphthalamide, the second polyamide,the polyester and the compatibilizer. The amount of polyphthalamide canalso range from about 3 to about 75 weight percent. For economicreasons, the range of about 2 to about 15 weight percent will also proveuseful.

The amount of the second polyamide, if present in the composition, iswithin the range of about 40 weight percent to about 75 weight percenton the basis of the on the basis of polyphthalamide, the secondpolyamide, the polyester and the compatibilizer. Other useful ranges areabout 45 to about 70 weight percent, and about 50 to about 65 weightpercent.

The amount of the aromatic polyester present in the composition is about3 weight percent to about 30 weight percent on the basis ofpolyphthalamide, the second polyamide, the polyester and thecompatibilizer. More useful amounts lie the range of 5 about weightpercent to about 30 weight percent, and about 6 weight percent to about25 weight percent.

The amount of the compatibilizer is within the range of about 12 weightpercent to about 30 weight percent on the basis of polyphthalamide, thesecond polyamide, the polyester and the compatibilizer. Other usefulranges are about 15 weight percent to 25 weight percent and about 15 to20 weight percent.

The fillers to be optionally used in this invention provide additionalstrength, reduced cost, reduced shrinkage and can be characterized byaspect ratios (AR) for each different shape. The aspect ratio is lengthof the largest dimension divided by the smallest dimension and definesthe general shape of the particle. Spherical and cubic fillers haveaspect ratios ranging from 1-2 and 1-4, respectively. Examples ofspherical and cubic fillers are calcium carbonate, precipitated calciumcarbonate, dolomite, magnesium carbonate, calcium silicate, bariumsulfate, glass beads—hollow and/or solid types, ceramic beads, naturaland synthetic silica, feldspar and nepheline-syenite, aluminumtrihydroxide and magnesium hydroxide, carbon black, wood flour,conductive coated particles and minerals.

Platy fillers have an aspect ratio ranging from 2-50. Examples ofsuitably fillers are talc, mica, kaolin, clay, and graphite. Acicularand fibrous fillers have aspect ratios ranging from 10-100 and >100,respectively. Examples of suitable acicular and fibrous fillers areWollastonite, Whiskers, chopped glass fibers, aramid fibers, carbonfibers, long glass fibers/roving and conductive metallic fibers.

The filler is also characterized by its average particle size andspecific surface which can be measured by liquid nitrogen adsorption(B.E.T method) or by permeability of air (Blaine method). The preferredaverage diameter is from 1 to 100 μm and the specific surface rangesbetween 1 m²/g to 800 m²/gm. Glass is a highly suitable filler. Glassfibers and glass spheres are examples of glass fillers.

The fillers are added in php units, where php is parts of the filler perhundred parts of the polymer which includes the polyphthalamide, thesecond polyamide, the aromatic polyester and compatibilizer.

As described in the examples, these compositions are made via reactiveextrusion. The reactive extrusion process for preparation of theformulation will normally comprise adding a dry blend mixture of thepolyphthalamide, the polyester, the modifiers and fillers and processingaids as a single feed into the feed hopper of a suitable mixing devicefor melt blending, such as a single or twin screw extruder or multiplemixing devices with controlled specific energy input via control of feedrate (15 to 95% torque), RPM (60 to 900 rpm), process temperature andresidence time distribution. The specific energy input will typically bewith the range of 0.4 to 0.8 kilowatt hours per kilogram and will moretypically be within the range of 0.45 to 0.6 kilowatt hours perkilogram.

Another concern about the plastic fuel tanks is that the solventproperties of the fuel extract materials from the amides. Thesematerials which extract from the fuel tank may be specific to the typeof fuel used and are characterized as fuel extractables, or thosecomponents which will leach out or extract from the fuel tank into thefuel. This problem can be solved, or at least dramatically minimized, bysubjecting the materials to an extraction process to remove theextractables prior to forming the part. Extraction before combining thematerials into the part is preferable over extracting the materials fromthe part because of the increased surface of the pellets and separatecomponents. This makes the extraction much more efficient.

The extraction process would use an extraction compound, likely asolvent, which would remove those fuel extractables of concern. The mostlikely compound would be the fuel itself, although it would not bedifficult to determine the ingredient in the fuel which removes the fuelextractables. Because different types of fuels (e.g. diesel vs.gasoline) are expected to have different extractions, the fuel to beused in the final container should be a starting extraction compound.Therefore, it is expected that a good extraction liquid a component ormixture of components of gasoline or diesel. The components of gasolineare generally hydrocarbons such n-paraffins, naphthenes, olefins, andaromatics. The aromatics are mostly benzene, ethyl-benzene, toluene, andthe xylenes. Other components of gasoline are ethanol, and tertiarybutylmethyl ether,

The extraction process could be a liquid-solid extraction process,whereby the pellets of the nylon 66 for example, would be passed throughthe liquid extraction compound, such as gasoline. It is well known thattime of contact, temperature of contact, lack of fuel extractables(purity) of the extraction compound, and area of contact (surface areaof the solid) are parameters which can be varied to increase theefficiency of the extraction.

A simple enabling process would place the pellets to be extracted into avessel, such as beaker. Gasoline would be added to the beaker and thepellets exposed to the gasoline at room temperature for sufficient timeto remove the fuel extractables to below the desired levels.

The Gasoline Extractables remaining in the pellets can be determined byfinely grinding the pellets, exposing them to fresh gasoline, removingthe gasoline with the fuel extractables, evaporating the gasoline andmeasuring the amount of material which did not evaporate. Complete andabsolute removal of the fuel extractables is not expected. Thepractitioner can determine when a satisfactory amount of fuelextractables remain by determining how much material is left over afterevaporating a known quantity of gasoline.

For example, one could take 10 grams of pellets ground to less than 20micron and expose them to 100 grams of gasoline for 6 hours. 10 grams ofgasoline would then be removed, placed in an evaporation dish and thegasoline evaporated with the fuel extractables remaining The weight ofthe fuel extractables per 100 grams of gasoline is easily determined bymultiplying the weight by 10. That number could be divided by the amountof ground pellets, in this case, 10 grams, to determine the amount offuel extractables per gram of pellets. The extraction could be runseveral times until the amount of fuel extractables removed is zero, oracceptably low for the practitioner. The amount of fuel extractables inthe ground pellets would then be the summation of the fuel extractablesremoved from each extraction.

For instance, if the first extraction yielded 0.09 grams FuelExtractables per gram, the second extraction yielded 0.004 grams, thethird yielded 0.0001, and the fourth yielded non-detected or to low tobe of concern, then the amount of Fuel Extractables in the sample wouldbe 0.09+0.004+0.0001=0.0941 grams of Fuel Extractables per gram ofpellets.

The design and application of solid-extraction processes can be found inChemical Engineer's Handbook, Perry & Chilton, and 5th Edition at 19-41to 19-44, which is herein incorporated by reference in its entirety.

Variations to the processes are well known in the art. For example, itis expected that efficiency per time can be increased by using a heatedextraction compound. It is also well known to cause the flow of theextraction compound to be counter to the flow of the material to beextracted. Such a flow is called countercurrent flow. It is also wellknown to increase the efficiency by increasing the surface area of thesolids. In this case, the practitioner could use any number of sizereducing techniques, such as simple grinding, to reduce the particlesize and increase the surface area for extraction.

It is also well known to reduce the operating costs by removing thecontaminated extraction compound, purifying it and re-introducing itinto the extraction vessel. In this case, the dirty gasoline would beremoved from the vessel, evaporated, leaving the fuel extractables,condensed, then reintroduced into extraction vessel. As described, inthe Handbook, this could be easily adapted for a continuous process. Oneskilled in the art can easily determine that a heated process ispreferred at the operating temperature just below the boiling point ofthe extraction compound.

After being extracted, the pellets could be optionally exposed to eitherheat or a driving force of vacuum or inert gas, or both to removeresidual extraction compound. If the pellets had been finely ground, itmay be preferable to re-form them into large pellets for easier usedownstream. If the pellets have not been ground, then they may used toform further products at any point along the stream.

The process for reducing the amount of fuel extractables in a materialused to manufacture a plastic container for organic liquids wouldcomprises the steps of

-   -   selecting at least one material used to manufacture the        container and    -   extracting at least some of the fuel extractables from the        material.        The process would specifically be an extraction process known as        a liquid-solid extraction wherein the compound used to the        manufacture the container is in its solid form and wherein the        liquid is comprised of an organic compound. The liquid would be        comprised of gasoline or diesel fuel and/or a component of        gasoline or diesel fuel.

A major use of the above composition is in plastic fuel tanks A fueltank will have at least one wall and at least two openings. The firstopening receives the fuel and is capable of receiving a cap. Often thecap is vented. If the cap is not vented, then the fuel tank may haveadditional openings for venting. Venting is necessary to prevent avacuum from forming and interfering with fuel flow out of the tankthrough the second opening.

These compositions and extraction process will find use in makingstorage vessels for organic compounds which are commonly known as fueltanks These fuel tanks, or containers for organic liquids, usually haveat least connection to an energy conversion device, such as a diesel,two or four cycle, or rotary engine, which consumes the fuel stored inthe container. The connection to the propulsion mechanism is done insuch a manner so that the organic liquid may be withdrawn from thecontainer and submitted to the energy conversion device where the fuelis converted to some form of mechanical energy. This can be succinctlydescribed as a container for organic liquids connected with an energyconversion device in such a manner that the organic liquid stored in thecontainer is capable of being transferred from the container to theenergy conversion mechanism.

This concept can be understood by examining the figures of thisspecification. In FIG. 1, 1A is the cap covering the inlet where thefuel, or liquid organic, is introduced into the tank. 1B is seam wherethe bottom half is welded or otherwise sealed to the top half If thecontainer is not welded, it may be injection molded or blown into themold and the seam 1B would be where the two halves of the mold cometogether. 1C is the top of the volumetric portion where the fuel, ororganic liquid, is actually stored. 1D is the mounting device whichattaches the container to the engine (the energy conversion device). Inthis case, the round circular mount encompasses the air cooler of theenergy conversion device. The air cooler is usually attached tocrankshaft of the engine. This is not the type of connection whichallows the transport of the fuel from the container.

In FIG. 2, 2A is the fuel tank cap covering the inlet where the fuel isintroduced into the tank. 2B is the welded or otherwise sealed seamjoining the top and bottom halves. If the container is not welded, itmay be injection molded or blown into the mold and the seam 2B would bewhere the two halves of the mold come together. 2C is volumetric storagewhere the fuel is actually contained. 2D is the mounting device stickingout and behind the tank as seen from the side view. 2E is the fueloutlet where the fuel is withdrawn from the tank. It is at this outletthat a tube would be used to connect this outlet with an inlet to theenergy conversion device. This tube is an example of the manner ofconnection that is capable of transporting the fuel from the containerto energy conversion device. It should be noted, the some fuel tankswill have the inlet and outlet in the cap.

In FIG. 3, 3A depicts the fuel cap. 3B depicts the seam or joiner wherethe two molded halves have been joined. If the container is not welded,it may be injection molded or blown into the mold and the seam 3B wouldbe where the two halves of the mold come together. 3C is the volumetricfuel storage. 3D is the mounting assembly. In the front view, themounting assembly is completely hidden and lies behind the tank itself3E is the fuel outlet and would be connected to the energy conversiondevice in a similar manner as 2E.

In FIG. 4, 4A is the fuel inlet. 4B is the seam where the two halves arejoined and welded or otherwise sealed together. If the container is notwelded, it may be injection molded or blown into the mold and the seam4B would be where the two halves of the mold come together. 4C is thevolumetric portion of fuel tank where the fuel is stored. 4D is themounting assembly. In this case the tank is molded to fit against apart. 4E is the fuel outlet.

Rather than flowing with gravity, the fuel would be withdrawn usingvacuum or a pump placed inside the tank, like many automotive tanks aretoday. The pump may also be located outside the tank as well.

Plastic fuel tanks can be made of different wall types. A multilayerwall combines different layers, each layer imparting differentproperties. In the multilayer wall, not all the layers may be plastic.For example, the outer plastic may be coated with a layer of metal. Amultilayer wall may be made by co-extruding the various layers orpre-extruding the layers and making the structure by laying one layeragainst the other. While the above composition could be a layer of amultilayer wall, it is more preferable to place it in a monolayer wall.A monolayer wall contains only one layer with the constituents dispersedthroughout the wall.

As a monolayer wall, the fuel tank can be manufactured using differenttechniques. The tank with a monolayer wall could be manufactured byinjection molding the composition into a part with very tighttolerances. The injection molding process is typical in the industry andrequires heating the composition to above its melting point in anextruder and introducing the liquid composition into the mold andletting it cool. In many cases the composition is injection molded intotwo halves and then assembled by welding or other means of attaching thetwo halves together. Because the composition can be blow molded, thetank may be made by extrusion blow or other blow molding techniques.

If the manufacturing process makes two halves of the tank, the halvesmay also be manufacturing by thermoforming or plug assist molding. Inthermoforming, the composition is cast into a sheet and the sheet formedinto the mold half and the finished part is then cut from the sheetleaving a web. After removal from the web, the two halves can be joined.

Rotational molding is another manufacturing process which eliminates theneed of welding or joining two halves. The rotational manufacturingprocess benefits greatly from the composition in the monolayerconstruction.

The following examples demonstrate the superiority of thesecompositions.

Example 1

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 92.65parts of nylon 6,6 Poly(hexamethylene adipamide), 7 parts of Royaltuf®485 maleic anhydride grafted EPDM from Crompton Corporation, 0.20 partsof ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 1.

TABLE 1 Properties Test Method Units Example 1 Tensile Modulus ASTM D638MPa. 1687 Tensile Strength @ Yield ASTM D638 MPa. 60.9 Tensile Strength@ Break ASTM D638 MPa. 52.3 Strain @ Break ASTM D638 % 21.3 FlexuralModulus ASTM D790 MPa. Flexural Stress ASTM D790 MPa. Notched Izod @ 23°C. ASTM D256 ft.lb/in 3.14 HDT @ 66 psi. ASTM D648 ° C. 221    @ 264psi. ° C.

Example 2

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 92.65parts of nylon 6,6 Poly(hexamethylene adipamide), 7 parts of Royaltuf®498 maleic anhydride grafted EPDM from Crompton Corporation, 0.20 partsof ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 2.

TABLE 2 Properties Test Method Units Example 2 Tensile Modulus ASTM D638MPa. 1810 Tensile Strength @ Yield ASTM D638 MPa. 64.5 Tensile Strength@ Break ASTM D638 MPa. 53.5 Strain @ Break ASTM D638 % 19.0 FlexuralModulus ASTM D790 MPa. Flexural Stress ASTM D790 MPa. Notched Izod @ 23°C. ASTM D256 ft.lb/in 2.75 HDT @ 66 psi. ASTM D648 ° C. 233    @ 264psi. ° C.

Example 3

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 84.66parts of nylon 6,6 Poly(hexamethylene adipamide), 14.94 parts ofRoyaltuf® 485 maleic anhydride grafted EPDM from Crompton Corporation,0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 3.

TABLE 3 Properties Test Method Units Example 3 Tensile Modulus ASTM D638MPa. 1553.8 Tensile Strength @ Yield ASTM D638 MPa. 49.6 TensileStrength @ Break ASTM D638 MPa. 42.5 Strain @ Break ASTM D638 % 27.6Flexural Modulus ASTM D790 MPa. Flexural Stress ASTM D790 MPa. NotchedIzod @ 23° C. ASTM D256 ft.lb/in HDT @ 66 psi. ASTM D648 ° C.    @ 264psi. ° C.

Example 4

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 79.68parts of nylon 6,6 Poly(hexamethylene adipamide), 19.92 parts ofRoyaltuf® 485 maleic anhydride grafted EPDM from Crompton Corporation,0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 4.

TABLE 4 Properties Test Method Units Example 4 Tensile Modulus ASTM D638MPa. 1600 Tensile Strength @ Yield ASTM D638 MPa. 47 Tensile Strength @Break ASTM D638 MPa. 42.3 Strain @ Break ASTM D638 % 31 Flexural ModulusASTM D790 MPa. 6.1 Flexural Stress ASTM D790 MPa. 24.2 Notched Izod @23° C. ASTM D256 ft.lb/in 16.2 HDT @ 66 psi. ASTM D648 ° C. 199 @ 264psi. ° C. 57

Example 5

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 74.84parts of nylon 6,6 Poly(hexamethylene adipamide), 18.71 parts ofCorterra® 200 Poly(trimethylene terephthalate), 3 parts of Royaltuf® 498maleic anhydride grafted EPDM from Crompton Corporation, 3 parts ofLotader® 8900 terpolymer of ethylene, methyl methacrylate and glycidylmethacrylate, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 5.

TABLE 5 Properties Test Method Units Example 5 Tensile Modulus ASTM D638MPa. 2096 Tensile Strength @ Yield ASTM D638 MPa. 61.1 Tensile Strength@ Break ASTM D638 MPa. 56.3 Strain @ Break ASTM D638 % 8.1 FlexuralModulus ASTM D790 MPa. 2468 Flexural Stress ASTM D790 MPa. 92.5 NotchedIzod @ 23° C. ASTM D256 ft.lb/in 1.53 HDT @ 66 psi. ASTM D648 ° C. 208 @264 psi. ° C. 66.3

Example 6

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 56.13parts of nylon 6,6 Poly(hexamethylene adipamide), 37.42 parts ofCorterra® 200 Poly(trimethylene terephthalate), 3 parts of Royaltuf® 498maleic anhydride grafted EPDM from Crompton Corporation, 3 parts ofLotader® 8900 terpolymer of ethylene, methyl methacrylate and glycidylmethacrylate, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 6.

TABLE 6 Properties Test Method Units Example 6 Tensile Modulus ASTM D638MPa. 2068 Tensile Strength @ Yield ASTM D638 MPa. 61.2 Tensile Strength@ Break ASTM D638 MPa. 59.2 Strain @ Break ASTM D638 % 8.0 FlexuralModulus ASTM D790 MPa. 2418 Flexural Stress ASTM D790 MPa. 89.5 NotchedIzod @ 23° C. ASTM D256 ft.lb/in 1.53 HDT @ 66 psi. ASTM D648 ° C. 199 @264 psi. ° C. 59.8

Example 7

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 37.42parts of nylon 6,6 Poly(hexamethylene adipamide), 56.13 parts ofCorterra® 200 Poly(trimethylene terephthalate), 3 parts of Royaltuf® 498maleic anhydride grafted EPDM from Crompton Corporation, 3 parts ofLotader® 8900 terpolymer of ethylene, methyl methacrylate and glycidylmethacrylate, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 7.

TABLE 7 Properties Test Method Units Example 7 Tensile Modulus ASTM D638MPa. 1999 Tensile Strength @ Yield ASTM D638 MPa. 50.3 Tensile Strength@ Break ASTM D638 MPa. 50.3 Strain @ Break ASTM D638 % 3.2 FlexuralModulus ASTM D790 MPa. 2450 Flexural Stress ASTM D790 MPa. 78.5 NotchedIzod @ 23° C. ASTM D256 ft.lb/in 0.35 HDT @ 66 psi. ASTM D648 ° C. 186 @264 psi. ° C. 58.9

Example 8

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 18.71parts of nylon 6,6 Poly(hexamethylene adipamide), 74.84 parts ofCorterra® 200 Poly(trimethylene terephthalate), 3 parts of Royaltuf® 498maleic anhydride grafted EPDM from Crompton Corporation, 3 parts ofLotader® 8900 terpolymer of ethylene, methyl methacrylate and glycidylmethacrylate, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 8.

TABLE 8 Properties Test Method Units Example 8 Tensile Modulus ASTM D638MPa. 1919 Tensile Strength @ Yield ASTM D638 MPa. 52.9 Tensile Strength@ Break ASTM D638 MPa. 52.8 Strain @ Break ASTM D638 % 3.9 FlexuralModulus ASTM D790 MPa. 2390 Flexural Stress ASTM D790 MPa. 75.4 NotchedIzod @ 23° C. ASTM D256 ft.lb/in 0.6 HDT @ 66 psi. ASTM D648 ° C. @ 264psi. ° C. 57.6

Example 9

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 49.10parts of nylon 6,6 Poly(hexamethylene adipamide), 16 parts of Corterra®200 Poly(trimethylene terephthalate), 25 parts of Royaltuf® 485 maleicanhydride grafted EPDM from Crompton Corporation, 3 parts of Lotader®4700, 5 parts of Lotader® 8900 terpolymer of ethylene, methylmethacrylate and glycidyl methacrylate, 1.5 parts of Phenoxy PKFE, 0.20parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 9.

TABLE 9 Properties Test Method Units Example 9 Tensile Modulus ASTM D638MPa. 851.4 Tensile Strength @ Yield ASTM D638 MPa. 29.6 Tensile Strength@ Break ASTM D638 MPa. 28.1 Strain @ Break ASTM D638 % 64.6 FlexuralModulus ASTM D790 MPa. 971.2 Flexural Stress ASTM D790 MPa. 38.1 NotchedIzod @ 23° C. ASTM D256 ft.lb/in 17.8 HDT @ 66 psi. ASTM D648 ° C. @ 264psi. ° C. 53.1

Example 10

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 50.1parts of nylon 6,6 Poly(hexamethylene adipamide), 11 parts of Corterra®200 Poly(trimethylene terephthalate), 29 parts of Royaltuf® 485 maleicanhydride grafted EPDM from Crompton Corporation, 3 parts of Lotader®4700, 5 parts of Lotader® 8900 terpolymer of ethylene, methylmethacrylate and glycidyl methacrylate, 1.5 parts of Phenoxy PKFE, 0.20parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 10.

TABLE 10 Properties Test Method Units Example 10 Tensile Modulus ASTMD638 MPa. 761 Tensile Strength @ Yield ASTM D638 MPa. 30.1 TensileStrength @ Break ASTM D638 MPa. 30 Strain @ Break ASTM D638 % 118.3Flexural Modulus ASTM D790 MPa. 837.4 Flexural Stress ASTM D790 MPa.34.2 Notched Izod @ 23° C. ASTM D256 ft.lb/in 17.4 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 51.3

Example 11

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 47.10parts of nylon 6,6 Poly(hexamethylene adipamide), 16 parts of Corterra®200 Poly(trimethylene terephthalate), 22 parts of Royaltuf® 485 maleicanhydride grafted EPDM from Crompton Corporation, 3 parts of Lotader®4700, 10 parts of Lotader® 8900 terpolymer of ethylene, methylmethacrylate and glycidyl methacrylate, 1.5 parts of Phenoxy PKFE, 0.20parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 11.

TABLE 11 Properties Test Method Units Example 11 Tensile Modulus ASTMD638 MPa. 768.6 Tensile Strength @ Yield ASTM D638 MPa. 31 TensileStrength @ Break ASTM D638 MPa. 30.9 Strain @ Break ASTM D638 % 106.5Flexural Modulus ASTM D790 MPa. 898.5 Flexural Stress ASTM D790 MPa.35.5 Notched Izod @ 23° C. ASTM D256 ft.lb/in 18.6 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 55.2

Example 12

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 50.60parts of nylon 6,6 Poly(hexamethylene adipamide), 16 parts of Corterra®200 Poly(trimethylene terephthalate), 25 parts of Royaltuf® 485 maleicanhydride grafted EPDM from Crompton Corporation, 3 parts of Lotader®4700, 5 parts of Lotader® 8900 terpolymer of ethylene, methylmethacrylate and glycidyl methacrylate, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 12.

TABLE 12 Properties Test Method Units Example 12 Tensile Modulus ASTMD638 MPa. 855.3 Tensile Strength @ Yield ASTM D638 MPa. 30.4 TensileStrength @ Break ASTM D638 MPa. 30.4 Strain @ Break ASTM D638 % 89.3Flexural Modulus ASTM D790 MPa. 960.1 Flexural Stress ASTM D790 MPa.38.4 Notched Izod @ 23° C. ASTM D256 ft.lb/in 17.6 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 52.2

Example 13

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 600 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 295° C. (Zone 4), 300° C. (Zone 5), 295°C. (Zone 6), 280° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with 79.68parts of nylon 6,6 Poly(hexamethylene adipamide), 19.92 parts of Amodel®AT 1002 Polyphthalamide, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.15 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 13.

TABLE 13 Properties Test Method Units Example 13 Tensile Modulus ASTMD638 MPa. 2241 Tensile Strength @ Yield ASTM D638 MPa. 75.9 TensileStrength @ Break ASTM D638 MPa. 75.9 Strain @ Break ASTM D638 % 4.2Flexural Modulus ASTM D790 MPa. 2688 Flexural Stress ASTM D790 MPa.106.7 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.01 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 75.5

Example 14

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 76.55 parts of nylon 6,6 Poly(hexamethyleneadipamide), 3 parts of Royaltuf® 485 maleic anhydride grafted EPDM fromCrompton Corporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.25 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 20 part ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 14.

TABLE 14 Properties Test Method Units Example 14 Tensile Modulus ASTMD638 MPa. 3846 Tensile Strength @ Yield ASTM D638 MPa. 122.8 TensileStrength @ Break ASTM D638 MPa. 122.8 Strain @ Break ASTM D638 % 3.8Flexural Modulus ASTM D790 MPa. 6183 Flexural Stress ASTM D790 MPa.159.8 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.09 HDT @ 66 psi. ASTMD648 ° C. 258 @ 264 psi. ° C. 243

Example 15

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 76.55 parts of nylon 6, 3 parts of Royaltuf® 485maleic anhydride grafted EPDM from Crompton Corporation, 0.20 parts ofELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.25 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 20 part ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 15.

TABLE 15 Properties Test Method Units Example 15 Tensile Modulus ASTMD638 MPa. 3968 Tensile Strength @ Yield ASTM D638 MPa. 113.2 TensileStrength @ Break ASTM D638 MPa. 113.4 Strain @ Break ASTM D638 % 3.6Flexural Modulus ASTM D790 MPa. 5428 Flexural Stress ASTM D790 MPa.141.4 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.25 HDT @ 66 psi. ASTMD648 ° C. 217 @ 264 psi. ° C. 198

Example 16

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 63.55 parts of nylon 6,6 Poly(hexamethyleneadipamide), 3 parts of Royaltuf® 485 maleic anhydride grafted EPDM fromCrompton Corporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.25 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 33 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 16.

TABLE 16 Properties Test Method Units Example 16 Tensile Modulus ASTMD638 MPa. 4033 Tensile Strength @ Yield ASTM D638 MPa. 122.3 TensileStrength @ Break ASTM D638 MPa. 122.9 Strain @ Break ASTM D638 % 3.6Flexural Modulus ASTM D790 MPa. 6473 Flexural Stress ASTM D790 MPa.151.3 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.12 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C.

Example 17

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 63.55 parts of nylon 6, 3 parts of Royaltuf® 485maleic anhydride grafted EPDM from Crompton Corporation, 0.20 parts ofELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.25 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 33 part ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 17.

TABLE 17 Properties Test Method Units Example 17 Tensile Modulus ASTMD638 MPa. 3767 Tensile Strength @ Yield ASTM D638 MPa. 104.2 TensileStrength @ Break ASTM D638 MPa. 104.1 Strain @ Break ASTM D638 % 3.5Flexural Modulus ASTM D790 MPa. 5543 Flexural Stress ASTM D790 MPa.131.3 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.24 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 197

Example 18

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 61.12 parts of nylon 6,6 Poly(hexamethyleneadipamide), 15.28 parts of Amodel® AT 1002 Polyphthalamide, 0.20 partsof ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 23 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 18.

TABLE 18 Properties Test Method Units Example 18 Tensile Modulus ASTMD638 MPa. 4518 Tensile Strength @ Yield ASTM D638 MPa. 148.2 TensileStrength @ Break ASTM D638 MPa. 148.2 Strain @ Break ASTM D638 % 4.0Flexural Modulus ASTM D790 MPa. 7192 Flexural Stress ASTM D790 MPa.203.3 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.05 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C.

Example 19

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 58.08 parts of nylon 6,6 Poly(hexamethyleneadipamide), 14.52 parts of Amodel® AT 1002 Polyphthalamide, 4 parts ofRoyaltuf® 485 maleic anhydride grafted EPDM from Crompton Corporation,0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 23 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 19.

TABLE 19 Properties Test Method Units Example 19 Tensile Modulus ASTMD638 MPa. 3176 Tensile Strength @ Yield ASTM D 638 MPa. 114 TensileStrength @ Break ASTM D638 MPa. 115 Strain @ Break ASTM D638 % 4.2Flexural Modulus ASTM D790 MPa. 5381 Flexural Stress ASTM D790 MPa.152.6 Notched Izod @ 23° C. ASTM D256 ft.lb/in 0.9 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 229

Example 20

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 45.84 parts of nylon 6,6 Poly(hexamethyleneadipamide), 15.28 parts of Amodel® AT 1002 Polyphthalamide, 15.28 partsof Corterra® 200 Poly(trimethylene terephthalate), 0.20 parts ofELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 23 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 20.

TABLE 20 Properties Test Method Units Example 20 Tensile Modulus ASTMD638 MPa. 4322 Tensile Strength @ Yield ASTM D 638 MPa. 133.3 TensileStrength @ Break ASTM D638 MPa. 133.6 Strain @ Break ASTM D638 % 3.8Flexural Modulus ASTM D790 MPa. 7025 Flexural Stress ASTM D790 MPa.168.7 Notched Izod @ 23° C. ASTM D256 ft.lb/in 0.87 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 227.3

Example 21

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 44.64 parts of nylon 6,6 Poly(hexamethyleneadipamide), 14.88 parts of Amodel® AT 1002 Polyphthalamide, 14.88 partsof Corterra® 200 Poly(trimethylene terephthalate), 5 parts of Lotader®8900 terpolymer of ethylene, methyl methacrylate and glycidylmethacrylate, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 20 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 21.

TABLE 21 Properties Test Method Units Example 21 Tensile Modulus ASTMD638 MPa. 3520 Tensile Strength @ Yield ASTM D 638 MPa. 125.4 TensileStrength @ Break ASTM D638 MPa. 125.4 Strain @ Break ASTM D638 % 4.4Flexural Modulus ASTM D790 MPa. 6549 Flexural Stress ASTM D790 MPa. 177Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.31 HDT @ 66 psi. ASTM D648 °C. @ 264 psi. ° C. 219

Example 22

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 42.84 parts of nylon 6,6 Poly(hexamethyleneadipamide), 14.28 parts of Amodel® AT 1002 Polyphthalamide, 14.28 partsof Corterra® 200 Poly(trimethylene terephthalate), 4 parts of Lotader®8900 terpolymer of ethylene, methyl methacrylate and glycidylmethacrylate, 4 parts of Royaltuf® 485 maleic anhydride grafted EPDMfrom Crompton Corporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 20 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 22.

TABLE 22 Properties Test Method Units Example 22 Tensile Modulus ASTMD638 MPa. 3056 Tensile Strength @ Yield ASTM D 638 MPa. 108.2 TensileStrength @ Break ASTM D638 MPa. 108.4 Strain @ Break ASTM D638 % 4.4Flexural Modulus ASTM D790 MPa. 5831 Flexural Stress ASTM D790 MPa.158.8 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.29 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 217

Example 23

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 50.68 parts of nylon 6,6 Poly(hexamethyleneadipamide), 21.72 parts of Corterra° 200 Poly(trimethyleneterephthalate), 3 parts of Lotader® 8900 terpolymer of ethylene, methylmethacrylate and glycidyl methacrylate, 4 parts of Royaltuf® 485 maleicanhydride grafted EPDM from Crompton Corporation, 0.20 parts of ELC-1010tetrakis methylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane fromEd-Lynn Network Polymers, and 0.20 parts of ELC-626 (also available asUltranox® 626 from Ciba Giegy) isbis(2,4-di-t-butylphenyl)pentaerythritol diphosphite stabilizer fromEd-Lynn Network Polymers. While 20 parts of chopped glass fibersVetrotex® 995 from Saint Gobain, was charged continuously at acontrolled rate from side feeder. The product was pelletized and driedat 80° C. for 4 hours to a moisture content of less than 0.05% byweight. Then, test specimens were made by injection molding and wereallowed to condition at a temperature of 23° C. for at least 48 hoursbefore testing.

The properties of the resulting compound are summarized in Table 23.

TABLE 23 Properties Test Method Units Example 23 Tensile Modulus ASTMD638 MPa. 3260 Tensile Strength @ Yield ASTM D 638 MPa. 116.1 TensileStrength @ Break ASTM D638 MPa. 115.8 Strain @ Break ASTM D638 % 4.4Flexural Modulus ASTM D790 MPa. 6100 Flexural Stress ASTM D790 MPa.156.1 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.19 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 231.8

Example 24

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 14.32 parts of Amodel® AT 1002 Polyphthalamide,58.08 parts of Corterra® 200 Poly(trimethylene terephthalate), 4 partsof Lotader® 8900 terpolymer of ethylene, methyl methacrylate andglycidyl methacrylate, 3 parts of Royaltuf® 485 maleic anhydride graftedEPDM from Crompton Corporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 20 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 24.

TABLE 24 Properties Test Method Units Example 24 Tensile Modulus ASTMD638 MPa. 3706 Tensile Strength @ Yield ASTM D 638 MPa. 119.5 TensileStrength @ Break ASTM D638 MPa. 119.5 Strain @ Break ASTM D638 % 4.0Flexural Modulus ASTM D790 MPa. 7566 Flexural Stress ASTM D790 MPa.151.3 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.27 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 201

Example 25

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 57.12 parts of nylon 6,6 Poly(hexamethyleneadipamide), 7.14 parts of Amodel® AT 1002 Polyphthalamide, 7.14 parts ofCorterra® 200 Poly(trimethylene terephthalate), 2 parts of Lotader® 8900terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate, 3parts of Royaltuf® 485 maleic anhydride grafted EPDM from CromptonCorporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 23 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 25.

TABLE 25 Properties Test Method Units Example 25 Tensile Modulus ASTMD638 MPa. 4501 Tensile Strength @ Yield ASTM D 638 MPa. 136.5 TensileStrength @ Break ASTM D638 MPa. 136.3 Strain @ Break ASTM D638 % 4.0Flexural Modulus ASTM D790 MPa. 7700 Flexural Stress ASTM D790 MPa.195.2 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.6 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 240

Example 26

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 54.10 parts of nylon 6,6 Poly(hexamethyleneadipamide), 8.40 parts of Amodel® AT 1002 Polyphthalamide, 7.0 parts ofCorterra® 200 Poly(trimethylene terephthalate), 2 parts of Lotader® 8900terpolymer of ethylene, methyl methacrylate and glycidyl methacrylate,4.5 parts of Royaltuf® 485 maleic anhydride grafted EPDM from CromptonCorporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 25 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 26.

TABLE 26 Properties Test Method Units Example 26 Tensile Modulus ASTMD638 MPa. 3432 Tensile Strength @ Yield ASTM D 638 MPa. 128.4 TensileStrength @ Break ASTM D638 MPa. 127.9 Strain @ Break ASTM D638 % 4.6Flexural Modulus ASTM D790 MPa. 6495 Flexural Stress ASTM D790 MPa.188.5 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.78 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 238

Example 27

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 31.71 parts of nylon 6,6 Poly(hexamethyleneadipamide), 13.59 parts of Corterra® 200 Poly(trimethyleneterephthalate), 6 parts of Royaltuf® 485 maleic anhydride grafted EPDMfrom Crompton Corporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 45 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 27.

TABLE 27 Properties Test Method Units Example 27 Tensile Modulus ASTMD638 MPa. 3960.3 Tensile Strength @ Yield ASTM D 638 MPa. 136.2 TensileStrength @ Break ASTM D638 MPa. 136.2 Strain @ Break ASTM D638 % 4.4Flexural Modulus ASTM D790 MPa. 9539.7 Flexural Stress ASTM D790 MPa.191 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.83 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 238.4

Example 28

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 27.18 parts of nylon 6,6 Poly(hexamethyleneadipamide), 18.12 parts of Corterra® 200 Poly(trimethyleneterephthalate), 8 parts of Royaltuf® 485 maleic anhydride grafted EPDMfrom Crompton Corporation, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 45 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 28.

TABLE 28 Properties Test Method Units Example 28 Tensile Modulus ASTMD638 MPa. 3725 Tensile Strength @ Yield ASTM D 638 MPa. 114 TensileStrength @ Break ASTM D638 MPa. 113.7 Strain @ Break ASTM D638 % 3.6Flexural Modulus ASTM D790 MPa. 9476.2 Flexural Stress ASTM D790 MPa.151 Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.59 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 228.2

Example 29

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 24 parts of nylon 6,6 Poly(hexamethyleneadipamide), 11.60 parts of Corterra® 200 Poly(trimethyleneterephthalate), 6 parts of Royaltuf® 485 maleic anhydride grafted EPDMfrom Crompton Corporation, 4 parts of Lotader® 8900 terpolymer ofethylene, methyl methacrylate and glycidyl methacrylate, 4 parts ofLotader® 4700, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 50 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 29.

TABLE 29 Properties Test Method Units Example 29 Tensile Modulus ASTMD638 MPa. 3414 Tensile Strength @ Yield ASTM D 638 MPa. 101 TensileStrength @ Break ASTM D638 MPa. 101 Strain @ Break ASTM D638 % 4.6Flexural Modulus ASTM D790 MPa. 9663.8 Flexural Stress ASTM D790 MPa.192 Notched Izod @ 23° C. ASTM D256 ft.lb/in 2.51 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 235.3

Example 30

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 29.6 parts of nylon 6,6 Poly(hexamethyleneadipamide), 12.0 parts of Corterra® 200 Poly(trimethyleneterephthalate), 4 parts of Royaltuf® 485 maleic anhydride grafted EPDMfrom Crompton Corporation, 2 parts of Lotader® 8900 terpolymer ofethylene, methyl methacrylate and glycidyl methacrylate, 2 parts ofLotader® 4700, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers. While 50 parts ofchopped glass fibers Vetrotex® 995 from Saint Gobain, was chargedcontinuously at a controlled rate from side feeder. The product waspelletized and dried at 80° C. for 4 hours to a moisture content of lessthan 0.05% by weight. Then, test specimens were made by injectionmolding and were allowed to condition at a temperature of 23° C. for atleast 48 hours before testing.

The properties of the resulting compound are summarized in Table 30.

TABLE 30 Properties Test Method Units Example 30 Tensile Modulus ASTMD638 MPa. 4090 Tensile Strength @ Yield ASTM D 638 MPa. 129.1 TensileStrength @ Break ASTM D638 MPa. 129 Strain @ Break ASTM D638 % 4.3Flexural Modulus ASTM D790 MPa. 9663.8 Flexural Stress ASTM D790 MPa.192 Notched Izod @ 23° C. ASTM D256 ft.lb/in 2.14 HDT @ 66 psi. ASTMD648 ° C. @ 264 psi. ° C. 240

Example 31

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 46.40 parts of nylon 6,6 Poly(hexamethyleneadipamide), 20.0 parts of Corterra® 200 Poly(trimethyleneterephthalate), 8 parts of Royaltuf® 485 maleic anhydride grafted EPDMfrom Crompton Corporation, 3 parts of Lotader® 8900 terpolymer ofethylene, methyl methacrylate and glycidyl methacrylate, 2 parts ofLotader® 4700, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers, 0.20 polyethylenewax (AC 540A from Honeywell Corporation) and 20.0 parts of Amodel® AT1002 Polyphthalamide. The product was pelletized and dried at 80° C. for4 hours to a moisture content of less than 0.05% by weight. Then, testspecimens were made by injection molding and were allowed to conditionat a temperature of 23° C. for at least 48 hours before testing.

The properties of the resulting compound are summarized in Table 31.

TABLE 31 Properties Test Method Units Example 31 Tensile Modulus ASTMD638 MPa. 1370.5 Tensile Strength @ Yield ASTM D 638 MPa. 55.2 TensileStrength @ Break ASTM D638 MPa. 52.1 Strain @ Break ASTM D638 % 10.2Flexural Modulus ASTM D790 MPa. 2040 Flexural Stress ASTM D790 MPa. 80.4Notched Izod @ 23° C. ASTM D256 ft.lb/in 1.6 HDT @ 66 psi. ASTM D648 °C. @ 264 psi. ° C. 66.5

Example 32

The main feeder of a ZE 25 twin screw extruder (L/D=44) operated at arate of 500 r.p.m. and a set temperature profile of 25° C. (feed), 250°C. (Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285°C. (Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270°C. (Zone 10), 265° C. (Zone 11), 265° C. (die), was charged with(through main hopper) 57.40 parts of nylon 6,6 Poly(hexamethyleneadipamide), 20 parts of Royaltuf® 485 maleic anhydride grafted EPDM fromCrompton Corporation, methyl methacrylate and glycidyl methacrylate, 2parts of Lotader® 4700, 0.20 parts of ELC-1010 tetrakismethylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)methane from Ed-LynnNetwork Polymers, and 0.20 parts of ELC-626 (also available as Ultranox®626 from Ciba Giegy) is bis(2,4-di-t-butylphenyl)pentaerythritoldiphosphite stabilizer from Ed-Lynn Network Polymers, 0.20 polyethylenewax (AC 540A from Honeywell Corporation) and 20.0 parts of Amodel® AT1002 Polyphthalamide. The product was pelletized and dried at 80° C. for4 hours to a moisture content of less than 0.05% by weight. Then, testspecimens were made by injection molding and were allowed to conditionat a temperature of 23° C. for at least 48 hours before testing.

The properties of the resulting compound are summarized in Table 32.

TABLE 32 Properties Test Method Units Example 32 Tensile Modulus ASTMD638 MPa. 1118.2 Tensile Strength @ Yield ASTM D 638 MPa. 47.7 TensileStrength @ Break ASTM D638 MPa. 41.1 Strain @ Break ASTM D638 % 23.3Flexural Modulus ASTM D790 MPa. 1719.2 Flexural Stress ASTM D790 MPa.66.8 Notched Izod @ 23° C. ASTM D256 ft.lb/in 15.2 HDT @ 66 psi. ASTMD648 ° C. 119.7 @ 264 psi. ° C. 65.3Examples 33 through 57 were prepared in the same manner as follows: themain feeder of a ZE 25 twin screw extruder (L/D=44) operated at a rateof 500 r.p.m. and a set temperature profile of 25° C. (feed), 250° C.(Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285° C.(Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270° C.(Zone 10), 265° C. (Zone 11), 265° C. (die), and the composition notedin Tables 33A, 33B, and 33C were each charged with through the mainhopper. The physical properties of the examples are noted in Table 34.

Compounds not identified previously are Epoxy 332, which is diglycidylether of bisphenol A available from The Dow Chemical Company; Fusabond PMD-353D, which is a random polypropylene copolymer with a melt flow rateof 450 g/10 minutes at 190° C., 2.16 Kg available from E.I. DuPont deMours, Inc.; Pearlthane® D11T93 which is polycaprolactone-copolyesterbased polyurethane from Merquinsa Corporation, Spain; Nitriimpact 1300which is methylmethacryatle-butadiene-styrene based rubbery modifier;Mark 135A which is isodecyl diphenyl phosphite available from CromptonCorporation; Naugard 412S which is a thioether (CAS No. 29589-76-3)available from Crompton Corporation; and Cloisite grades 25A, 93A, and30B which are natural montmorillonite modified with quatenary saltsavailable from Nanoclay Corporation. Grade 25A modified with dimethyl,hydrogenated tallow, 2-ethylexyl quaternary ammonium. The anion isammonium. Grade 30B is modified with methyl, tallow, bis-2-hydroxyethyl,quaternary ammonium with chloride anion. Grade 93A is methyl,dehydrogenated tallow ammonium with HSO₄ anion.

TABLE 33A Examples and Amounts of Compounds in pph of the compositionExample Number Compound 33 34 35 36 37 38 39 40 Nylon 66 94.65 92.6592.65 92.65 92.65 84.66 79.68 94.60 D11T93 5.00 5.00 5.00 Phenoxy ® 2.00PKFE Lotader ® 2.00 4700 Royaltuff ® 7.00 0.00 14.94 19.92 485Royaltuff ® 7.00 498 Ultranox ® 0.25 0.25 0.25 0.25 0.25 626 ELC ® 10100.10 0.10 0.10 0.10 0.10 Mark ® 135 A 0.20 0.20 0.20 Naugard ® 0.20 0.200.20 412 S Cloisite ® 25A 5.00

TABLE 33B Examples and Amounts of Compounds in pph of the compositionExample Number Compound 41 42 43 44 45 46 47 48 Nylon 66 94.60 94.6093.60 93.60 93.60 0.00 0.00 0.00 Mark ® 135 A 0.20 0.20 0.20 0.20 0.200.20 0.20 0.20 Naugard ® 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 412 SEpoxy 332 0.00 0.00 1.00 1.00 1.00 0.00 0.00 0.00 Nylon 6 94.60 94.6094.60 Cloisite ® 5.00 25A Cloisite ® 5.00 5.00 5.00 93A Cloisite ® 5.005.00 5.00 30B

TABLE 33C Examples and Amounts of Compounds in pph of the compositionExample Number Compound 49 50 51 52 53 54 55 56 57 Nylon 66 92.60 73.6069.40 57.40 49.40 46.40 65.30 61.30 0.00 Phenoxy ® PKFE 4.00 Lotader ®4700 2.00 2.00 2.00 4.00 4.00 2.00 Lotader ® 8900 3.00 3.00 Royaltuff ®485 20.00 8.00 20.00 8.00 8.00 20.00 Corterra ® 200 (PTT) 20.00 30.0030.00 54.30 Ultranox ® 626 0.20 0.20 0.20 0.20 0.50 0.50 0.50 ELC 10100.20 0.20 0.20 0.20 0.20 0.20 0.20 Mark 135 A 0.20 0.20 Naugard ® 412 S0.20 0.20 Epoxy 332 2.00 1.00 Amodel ® At 20.00 20.00 20.00 20.00 20.001002 Cloisite ® 30B 5.00 5.00 HDPE 20.00 AC 540A wax 0.20 0.20 0.20 0.20Fusa bond P 2.00 MD-353D

TABLE 34 Physical Properties of Compositions Tensile Tensile Tensile Str@ Tensile Flex Flex Izod Ex. Mod. Str @ Brk Str at Mod, Stres Impact HDT@ HDT No Mpa Yld Mpa Mpa brk (%) MPa Mpa @ RT 66 psi @ 264 psi 33 213968.9 49.5 25.3 2453 93.7 0.96 222 34 1950 68.3 63.0 15.8 2624 100.5 1.37221 35 1662 68.1 62.3 13.7 2617 99.3 1.07 217 36 1687 60.9 52.3 21.32350 88.0 3.14 221 61.3 37 1810 64.5 65.3 19.0 2443 96.6 2.75 233 65.238 2672 68.0 14.6 214 62.0 39 1600 47.0 42.3 31.0 1641 62.3 16.2 19958.9 40 2220 85.8 85.8 4.3 3779 128 0.69 88.1 41 2560 84.0 84.0 4.1 3676126 0.69 87.2 42 2248 87.7 87.7 4.8 3764 128 0.60 89.8 43 2136 89.3 89.34.8 3672 131 0.86 86.4 44 2136 89.4 89.4 5.0 3604 129 0.84 84.3 45 222492.3 91.7 5.3 3626 131 0.78 84.7 46 2249 75.1 75.0 25.0 2959 110 1.0561.6 47 2134 75.3 9.6 35.0 3010 107 0.93 70.8 48 2183 73.6 14.6 33.03177 112 0.95 74.2 49 2745 91.6 91.6 4.5 3680 129 0.48 78.9 50 1876 48.044.6 14.5 2225 75.2 3.14 64.5 51 1531 65.4 57.3 15.3 2372 92.5 2.67 70.552 1118 47.7 41.1 23.3 1720 66.8 15.2 120 65.3 53 1049 48.4 37.2 30.51499 61.6 2.8 66.7 54 1371 55.2 52.1 10.2 2040 80.4 1.6 66.5 55 160565.3 62.4 7.2 2308 89.9 0.6 67.7 56 1617 65.2 52.4 11.5 2241 89.8 1.0868.3 57 768 23.0 23.0 4.8 1032 35.1 0.86 51.2

Examples 4, 31 and 32 were injection molded into plaques and cut intothe same shape and thickness to conforming to ASTM specification D814-95. Organic Vapor Transmission was established per ASTM D 814-95.The results are in Table 35 that shows the weight of the filled vesselsealed with the composition of each example at each corresponding time.The superiority of the composition is demonstrated in Example 32 whichshows no loss in weight after reaching equilibrium 96 hours at 40° C.This shows that there was no fuel lost to the atmosphere after reachingequilibrium at 24 hours.

Shrinkage of the material was measured by comparing the dimensions ofthe mold with the dimensions of the finished cooled part after 24 hrs.Shrinkage was measured in the flow direction and is expressed as apercent of the corresponding mold dimension in Table 35.

TABLE 35 Weight Of Container (gms) and Material Shrinkage InitialShrinkage Weight 24 hrs 48 hrs 96 hrs (%) Flow Sample @ 23° C. @ 40° C.@ 40° C. @ 40° C. Direction Example 4 327.75 327.7 327.7 327.65 1.28Example 31 324.30 324.25 324.20 324.20 1.15 Example 32 322.15 322.0322.0 322.0 1.14

Examples 58 through 63 were prepared in the same manner as follows: themain feeder of a ZE 25 twin screw extruder (L/D=44) operated at a rateof 500 r.p.m. and a set temperature profile of 25° C. (feed), 250° C.(Zone 2), 275° C. (Zone 3), 280° C. (Zone 4), 285° C. (Zone 5), 285° C.(Zone 6), 275° C. (Zone 7), 270° C. (Zone 8), 270° C. (Zone 9), 270° C.(Zone 10), 265° C. (Zone 11), 265° C. (die), and the composition notedin Tables 36A, 36B, and 36C were each charged with through the mainhopper. The physical properties of the examples are noted in Table 37.

TABLE 36 Examples and Amounts of Compounds in pph of the compositionExample Number Compound 58 59 60 61 62 63 Nylon 66 46.40 61.3 60.5576.60 63.15 57.15 Phenoxy ® PKFE 2.00 3.00 3.00 Lotader ® 8900 3.00 2.003.00 3.00 Royal tough 485 20.00 20.00 22.00 22.00 Corterra ® 200 10.006.00 (PTT) Royal tough ® 498 20.00 20.00 20.00 Ultranox ® or ELC ® 0.300.25 0.25 0.20 0.15 0.15 626 ELC ® 1010 0.20 0.20 0.20 0.20 0.20 0.20Amodel ® At 1002 15.00 Amodel ® At 1006 8.00 Cloisite ® 30B 3.23 AC 540Awax 0.10 Polyethylene 15.00 Terephthalate Bynel ® CSX E418 3.00Nystlan ® 0.30 0.30 Black 900 0.20 0.20

In the case of Example 59, the Cloisite 30B was precompounded into theNylon 66.

TABLE 37 Physical Properties of Compositions Tensile Tensile Tensile Str@ Tensile Flex Flex Izod Ex. Mod. Str @ Brk Str at Mod, Stres Impact HDT@ HDT No Mpa Yld Mpa Mpa brk (%) MPa Mpa @ RT 66 psi @ 264 Psi 58 119141.0 35.8 26.9 1639 62.6 12.20 61.3 59 1613 51.7 45.9 21.6 1849 70.411.00 61.3 60 1585 43.9 42.1 17.7 1732 62.5 1.99 60.0 61 1505 46.1 42.930.3 1511 59.3 13.60 58.4 62 1299 38.6 37.9 47.1 1499 54.7 17.60 74.3 631320 42.0 38.4 26.7 1520 58.0 17.30 78.6

These examples were additionally analyzed for their ability to absorbcomponents of gasoline. The more the material absorbed over time, themore permeable the composition is expected to be.

As can be seen in Table 38, the non-polyphthalamide polyamide (Ex 61,and 64) absorbs a tremendous amount of material and is thereforeexpected to have poorer barrier than the composition containing eitherthe polyphthalamide (59) or polyester (58 and 60).

TABLE 38 Weight Gain of Sample (Percent) Sample 7 day 14 days 21 days 28days 58 0.23 0.55 59 0.27 0.66 60 0.25 0.65 61 0.68 0.78 0.93 64 1.462.71 3.61

1. A container for organic liquids having a contained volume whereinsaid container is a fuel tank comprised of at least one wall, an inlet,an outlet, wherein the wall is comprised of a thermoplastic compositionwhich includes an aromatic polyester selected from the group consistingof polybutylene terephthalate, polyethylene terephthalate,polytrimethylene terephthalate, polyethylene naphthalate, andpolybutylene naphthalate and copolymers thereof, a first polyamide whichis a polyphthalamide, a compatibilizer having at least one functionalgroup selected from the group consisting of hydroxyl groups, carboxylicacid groups, glycidyl groups, maleic anhydride groups, amino groups,siloxane groups or isocyanato groups and a second polyamide selectedfrom the group consisting of aliphatic polyamides and partially aromaticpolyamides; wherein the aromatic polyester is present at a level withinthe range of 3 weight percent to 30 weight percent on the basis of thepolyphthalamide, the second polyamide, the polyester and thecompatibilizer; wherein the second polyamide is present at a levelwithin the range of 40 to 75 weight percent on the basis of thepolyphthalamide, the second polyamide, the polyester and thecompatibilizer and wherein the polyphthalamide is present at level of atleast 3 weight percent on the basis of the polyphthalamide, the secondpolyamide, the polyester and the compatibilizer.
 2. The container ofclaim 1, wherein the wall of the container is of a monolayerconstruction.
 3. The container of claim 1, wherein the inlet is capableof receiving a cap.
 4. The container of claim 2, wherein the inlet iscapable of receiving a cap.
 5. The container of claim 1, wherein thecontainer is manufactured by blow molding.
 6. The container of claim 1,wherein the container is manufactured by rotational molding.
 7. Thecontainer of claim 1, wherein the container is manufactured by injectionmolding.
 8. The container of claim 1, wherein the container has a weldseam.
 9. The container of claim 1, wherein the container has a seamwhere the two halves of the mold used to make the container have cometogether.
 10. The container of claim 2, wherein the container ismanufactured by blow molding.
 11. The container of claim 2, wherein thecontainer is manufactured by rotational molding.
 12. The container ofclaim 2, wherein the container is manufactured by injection molding. 13.The container of claim 2, wherein the container has a weld seam.
 14. Thecontainer of claim 2, wherein the container has a seam where the twohalves of the mold used to make the container have come together. 15.The container of claim 4, wherein the container is manufactured by blowmolding.
 16. The container of claim 4, wherein the container ismanufactured by rotational molding.
 17. The container of claim 4,wherein the container is manufactured by injection molding.
 18. Thecontainer of claim 4, wherein the container has a weld seam.
 19. Thecontainer of claim 4, wherein the container has a seam where the twohalves of the mold used to make the container have come together.